Soft Shaped Tortillas: Structural Integrity and Shelf Life
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Solution Overview
Problem
Consumers face challenges with existing soft bread options that are either too thick, prone to breaking, or high in fat, and lack convenience and shelf stability, making them unsuitable for holding fillings and serving as healthy, convenient food choices.
Innovation Solution
Development of a low-fat, shelf-stable soft tortilla product formed into various three-dimensional shapes that are rigid yet flexible, allowing for easy filling and handling, made from chemically leavened cooked cereal dough with specific moisture and water activity levels, and packaged in a modified atmosphere to maintain freshness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional soft bread options are used, then they provide a soft texture, but they are either too thick, prone to breaking, or high in fat
Solution Approach 1:
The patent changes the physical and chemical parameters of the tortilla by controlling moisture content (20-30%) and water activity (0.90-0.95), using chemically leavened cooked cereal dough to achieve optimal softness and structural integrity simultaneously
Solution Approach 2:
The tortilla uses a composite formulation combining cereal dough with specific moisture and fat content ratios, creating a material that balances softness with structural strength without excessive thickness
2Duration of action of stationary object
If traditional bread options are used, then they provide immediate availability, but they lack shelf stability and dry out quickly
Solution Approach 1:
The patent optimizes moisture content (20-30%) and water activity (0.90-0.95) parameters to extend shelf life while preventing the tortilla from drying out, achieving both long-term storage stability and moisture retention
Solution Approach 2:
The tortilla is packaged in a modified atmosphere with reduced oxygen levels (1-10% oxygen, 90-80% nitrogen), creating an inert environment that prevents oxidation and moisture loss, thereby extending shelf life while maintaining composition stability
3Shape
If tortillas are microwaved to form shapes, then shaping is achieved, but the tortilla becomes hard and excessively tough
Solution Approach 1:
The patent controls the heating parameters (temperature and time) to achieve shaping without overcooking, maintaining the tortilla's soft texture while forming the desired three-dimensional shape
Solution Approach 2:
The tortilla is pre-formed into three-dimensional shapes during manufacturing using chemically leavened cooked cereal dough, eliminating the need for post-cooking shaping that would compromise texture quality
4Ease of operation
If conventional tortillas are used, then they are flexible and easy to fold, but managing filling amount and sealing is challenging
Solution Approach 1:
The tortilla is pre-formed into three-dimensional shapes (cups, bowls, boats) during manufacturing, which pre-establish the containing structure, making filling management easier and eliminating complex folding and sealing steps by the consumer
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a convenient, healthy, and mess-free way to hold fillings, maintaining a soft texture while retaining shape without frying, offering improved portability and longer shelf life compared to traditional bread options.
Implementation Method 1
a low fat shelf stable soft tortilla fabricated from a Mexican tortilla such as a chemically leavened cooked cereal dough
Implementation Method 2
packaged in a modified atmosphere to maintain freshness
Data Source
AI summary
The present invention encompasses edible carriers for foods that are soft but still hold a preformed shape. Specifically encompassed are soft shaped tortilla products that can be used to hold food fillings. Exemplary shapes and sizes are provided for the products. Also encompassed are methods of making, packaging, and using the products.